Fiber-Reinforced Hose Binder Resin for Fast, Uniform Extrusion
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Solution Overview
Problem
Current hose assembly manufacturing processes are slow, capital-intensive, and prone to quality issues such as inhomogeneous mixtures and burst strength inconsistencies, particularly when dealing with thermoset rubber compounds and extreme environmental conditions, limiting the production of cost-effective, time-efficient hose assemblies that can safely transfer pressurized fluids.
Innovation Solution
Fiber-reinforced composites with low viscosity and molecular weight resin-binders, such as metallocene polyethylene or polypropylene, are used to treat reinforcement fibers, filling interstices and improving compatibility between fibers and polymeric matrices, allowing for continuous extrusion and cross-linking to enhance mechanical properties and reduce processing artifacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset rubber compounds are used in multi-step cross-head extrusion process, then hose assemblies can be manufactured with reinforcement layers, but the manufacturing process becomes slow and capital intensive
Solution Approach 1:
The patent employs continuous extrusion processes for both the thermoplastic matrix and reinforcement fibers, eliminating the batch-mode operations and discrete steps of traditional thermoset hose manufacturing. This continuous action maintains production momentum and significantly increases manufacturing throughput while preserving structural integrity through consistent material properties throughout the hose assembly.
Solution Approach 2:
The patent replaces the complex multi-step mechanical cross-head extrusion system with a simplified single-screw or twin-screw extruder configuration. This substitution reduces equipment complexity, capital investment, and operational time while achieving equivalent or superior mixing and distribution of reinforcement fibers within the thermoplastic matrix.
2Ease of manufacture
If batch mode dry blending of rubber materials is used, then processing is simpler, but inhomogeneous mixtures and quality inconsistencies occur
Solution Approach 1:
The patent replaces batch-mode mechanical dry blending with continuous melt mixing within the extruder barrel. The thermoplastic matrix is melted and mixed with reinforcement fibers under controlled temperature and shear conditions, ensuring homogeneous distribution throughout the entire production run. This eliminates the inhomogeneity problems inherent in batch dry blending while maintaining operational simplicity.
Solution Approach 2:
The patent changes the physical state of the matrix material from solid (batch blending) to molten (extrusion mixing), fundamentally altering the mixing mechanism. The molten thermoplastic provides superior flow and distribution characteristics, ensuring uniform reinforcement fiber dispersion. Temperature and shear rate parameters are optimized to achieve consistent mixing without compromising processing ease.
3Strength
If brass coated wire reinforcement is used, then mechanical strength is improved, but chemical bonding is interfered with by moisture
Solution Approach 1:
The patent changes the matrix material from moisture-sensitive thermoset rubber to moisture-resistant thermoplastic polymer. This fundamental material parameter change eliminates the moisture interference problem that plagues thermoset systems. The thermoplastic matrix provides consistent chemical bonding to reinforcement fibers without the hygroscopic issues that cause variable bond strength in rubber-based systems.
Solution Approach 2:
The patent creates a composite system using thermoplastic matrix combined with reinforcement fibers (such as glass, aramid, or steel). This composite approach maintains the mechanical strength benefits of traditional wire reinforcement while the thermoplastic component provides moisture resistance and consistent bonding characteristics, eliminating the reliability issues associated with brass-coated wire in humid environments.
4Stability of the object's composition
If steam autoclave cross-linking is performed for one hour, then thermoset rubber is properly cured, but production time and capital costs increase
Solution Approach 1:
The patent replaces the thermal steam autoclave curing system with a mechanical extrusion and cooling system. The thermoplastic matrix is extruded in a molten state, allows reinforcement fibers to set in position, then cools and solidifies rapidly at ambient or controlled temperatures. This eliminates the one-hour steam autoclave cycle entirely, reducing production time from hours to minutes while achieving equivalent structural stability through controlled cooling and crystallization of the thermoplastic material.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The approach results in hose assemblies with improved tensile strength and flexural modulus, reducing failure modes associated with traditional mandrel processing and enabling the safe transfer of pressurized fluids under extreme conditions without compromising long-term usage.
Implementation Method 1
the one or more resin-binders, having sufficiently low molecular weight and viscosity, can fill or otherwise reduce interstices, voids, air bubbles, or flaws within the reinforcement fiber
Implementation Method 2
thereby reducing interfacial surface tension and providing greater compatibility between the materials
Implementation Method 3
The one or more resin-binders of the composites can be cross-linked to provide desired properties for end-use applications
Data Source
AI summary
A flexible fiber reinforced hose adapted for conveying fluids under pressure. The reinforced hose having a core tube having at least one reinforcement layer surrounding an outer core tube surface. Each reinforcement layer having one or more woven mats, unwoven mats, or bundle of fibers comprising a plurality of reinforcement fibers that has a binder-resin filling at least a portion of the voids of the reinforcement fibers. In some aspects, the binder-resin adheres to the reinforcement fibers and displaces the air voids at the interface between the reinforcement fibers and the binder-resin. The binder-resin has a relatively low viscosity less than at least about 20,000 centipoise at 176° C. and low molecular weight, which allows the reinforcement layer to maintain a low flex modulus while maintaining or increasing tensile modulus. The reinforced hose also has at least one polymer layer that bonds to the binder-resin of the reinforcement layer, preferably being cross-linkable or cross-linked to the polymer layer.